Life Cycle Assessment for Bygen: Setting a New Benchmark for Sustainable Activated Carbon

Bygen, a pioneering company focused on sustainable materials innovation, has developed a novel activated carbon production process that uses almond shell biomass instead of coal. Recognising the need to demonstrate the credibility of its environmental performance to stakeholders, the company commissioned Minviro to conduct an independent Life Cycle Assessment (LCA). The aim was not only to verify Bygen’s sustainability claims but also to establish a transparent, ISO-aligned benchmark for the industry.

Conventional activated carbon production is dominated by coal-based feedstocks, a process that comes with significant climate impacts. Typical emissions reach approximately 11.1 kilograms of carbon dioxide equivalent for every kilogram of activated carbon produced, creating an industry standard that is environmentally costly. Bygen’s ambition was to prove that its biomass-based process could deliver an order-of-magnitude reduction in emissions, creating a pathway away from coal while providing the same essential functionality required in industries such as water treatment and pollution control.

Minviro’s study applied cradle-to-gate boundaries to capture the carbon footprint of Bygen’s technology, covering Scope 1, Scope 2 and selected Scope 3 emissions in line with ISO 14040, 14044 and 14067 standards. By focusing on robust data quality, methodological transparency and adherence to international best practice, the assessment ensured that the results could be directly compared with conventional activated carbon production pathways.

The results demonstrated that Bygen’s almond shell–based process achieved an impact of just 0.37 kilograms of carbon dioxide equivalent per kilogram of activated carbon produced. Compared to the coal-based benchmark of roughly 11.1 kilograms, this finding represents a reduction of nearly ninety-seven percent in climate change impact. Even without including additional benefits from the sequestration of carbon in biomass feedstocks, Bygen’s process achieved a level of performance that establishes a new benchmark for activated carbon.

Dr. Lewis Dunnigan, Bygen’s Managing Director and co-founder, commented on the significance of these findings: “The LCA results confirm that Bygen’s technology offers a genuine pathway to sustainable activated carbon, helping industries transition away from coal-based products while contributing to global carbon reduction goals.” His statement underscores how independent scientific validation strengthens Bygen’s ability to demonstrate impact to investors, customers and partners while reinforcing the company’s mission to accelerate the decarbonisation of supply chains.

For Minviro, the study also highlights the value of rigorous, independent assessment in shaping credible sustainability narratives. As Senior LCA Analyst Rachel Harris explained: “Bygen’s results demonstrate the importance of rigorous LCA in validating sustainability claims. This study shows how innovative activation technologies can substantially lower carbon footprints, setting a new benchmark for the sector.” The perspective reinforces Minviro’s role as a trusted partner in translating technical results into insights that support credible communication and decision-making.

The implications of the study extend far beyond a single production pathway. Bygen’s results show that it is possible to slash emissions from activated carbon by almost ninety-seven percent, offering immediate opportunities for industries to reduce their embedded carbon footprints. From water treatment to PFAS remediation, sectors dependent on activated carbon now have a viable alternative to coal-based products that combines technical performance with robust environmental credentials. Beyond its direct applications, the case illustrates the systemic potential of biomass-based processes to transform supply chains and reduce climate burdens across multiple industries.

Looking ahead, Bygen is preparing to scale its technology globally, leveraging the LCA as both a technical validation and a communication tool. With continued support from Minviro, the company can further refine its environmental assessments, optimise processes, and develop additional case studies that illustrate the transformative potential of its approach. For Minviro, this project exemplifies how independent, science-driven analysis can help position innovators at the forefront of the low-carbon transition while building trust across markets.

Bygen’s collaboration with Minviro demonstrates that sustainability claims are most powerful when underpinned by rigorous, ISO-aligned evidence. Together, the two organisations have shown that activated carbon, a material long associated with high emissions, can instead become a driver of meaningful climate impact reduction. The case sets a clear example for how other industries can validate their innovations, communicate credibly, and accelerate the global transition towards sustainable supply chains.